Surface Roughness Modelling in Machining Processes

Surface Roughness (Ra) is not only an index of product quality but also it is widely used as a reference in technical requirements for machining products. A statistical regression model was defined using only cutting parameters. A Design of Experiments (DoE) based on the Response Surface Methodology (RSM) was implemented. The resulting model covers a wide machining domain with several cutting tools diameters and different Aluminum alloys. The cutting tool condition is included in the model. These models allow predictions of Ra with small error (12.8 %). Optimal cutting conditions can be found by exploiting the model and using genetic algorithm technique. Intensive experimentation using an industrial High Speed Machining center validates the results.